Integrally molded recyclable video tape cassette

ABSTRACT

An integrally molded tape cassette has a base with vertical first and second side walls. A rear wall is attached to the base by an integral hinge. A cover attached to the rear wall by an integral hinge, and a dust door attached to the cover by an integral hinge. Snaps between the cover and base connect and close the apparatus with integral springs pressing on tape reel hubs. The dust door covers a forward wall protruding from the base between the first and second side walls. The forward wall has slots and posts for allowing passing of the tape between the interior and exterior of the cassette. The cassette further includes a dust door latch which is integrally molded with one of the sides of the tape. An integrally molded tape hub brake is positioned between the hubs for locking the hub flanges when the cassette is not in use.

BACKGROUND OF THE INVENTION

This invention relates to recyclable low cost video cassettes.

The numbers of households and businesses with standard format video tape cassette players is very large and is expected to increase shortly to substantially full saturation in 80% or more of households and businesses. Many households and businesses have more than one video tape cassette player. Each of the cassette players is a potential user of many cassettes. Many of the cassettes will be used only once or only a few times. The infrequently used cassettes are usually constructed in the same manner as frequently used cassettes.

The cassette players offer a resource for short term information and advertising. For advertising tapes having only small numbers of plays, cassette housings reels and brakes are available only in full-cost conventional designs, which add to the cost of what otherwise might be low cost advertising media. For example, the cost of the cassettes may far outweigh the cost of producing, planning and delivering advertising tapes to prospective customers for goods and services. It is expected that such advertising cassettes may be used once or twice and then destroyed.

Currently available standard video cassettes are made of up to 37 parts. The parts which make up the cassette are of different construction and different types of materials. That makes it difficult to salvage and recycle the materials when the cassettes are thrown away.

Standard video cassette made with 37 parts have equal numbers of assembly steps and assembly stations. The number of assembly steps and stations is directly related to the cost of manufacturing the video cassettes.

The cost of producing the individual parts and of assembling the separate parts increases the cost of the cassettes.

A need exists for a cassette housing which is made out of material which may be readily recycled without disassembling the cassette. Similarly, a need exists for a low cost video cassette to take advantage of the market that exists for low price prerecorded cassettes and free distribution cassettes used to advertise products and services.

SUMMARY OF THE INVENTION

The present invention provides the low cost video cassette housing of uniformly manufactured compatible materials which will easily be recyclable and in which the principal components are made in a single mold and are assembled by rapid uniform motions. The housing and the hub locks are made in a single cavity, and the housing and reels are made of similar material. Supplementary metal options can be included in order to enhance the performance of the low cost video cassette. These options include supports and springs which are designed to be easily removable for recycling of both the housing and the metal parts. When a device has been used, the entire device may be easily recycled with other plastic materials. The plastic cassette may then be crushed, ground and reformed into other useful devices. The magnetic recording tape preferably is pulled from the reels before disposal.

Assembly steps are limited to removing the entire cassette from a mold, dropping reels into place, with leaders extending from the cassette housing, and then folding the back upward, and folding the cover downward until the cover snaps in place. The cassette is ready for use by attaching a prerecorded magnetic tape to the leaders. This, of course is in the present invention's most basic variation. Some other optional added parts would variate the steps for assembly.

Alternately, the magnetic tape may be pre-attached to leaders and the reels, before the reels and tape are dropped into place in the housing. The cover is then folded inward, and the rear wall and cover are snapped into place in a single continuous motion to ready the cassette for usage.

The preferred cassette housing is made in one continuous piece with living hinges between the pieces, which include the base, side walls, front wall, rear wall, cover, dust door sides, hub lock, pressure flap and dust door latch. Each reel hub combination can be made in one or two pieces which snap or weld together. An alternate hub lock is made in a single piece, which folds together and attaches to a preformed configuration in the housing base. All of the materials are made of single or compatible plastic materials.

A preferred video tape cassette housing incorporates a base, a rear wall, and first and second opposite side walls connected to the base. A cover is connected to the rear wall, and a dust door is connected to the cover. The side edges of the rear wall engage the rear edges of the side wall, and the side edges of the cover contact the upper edges of the side walls. The dust door is hinged on the cover for permitting movement of the cover between a raised position and a lowered position to thereby expose or cover a magnetic tape protruding from the front of the cassette housing.

The hinges between the sections of the cassette are living hinges which are integrally formed between these sections. The living hinges allow a more efficient molding process and sufficiently decrease the number of parts used in the prior art.

In one form, the cover is made with large, spaced openings and with hub springs which extend inward from the openings. The hub springs are molded to extend inward and downward into the casing when the cover is assembled on the base.

In another form, the housing further includes first and second leaf springs hinged near side edges of the cover. In one form, the springs fold inward and rest atop hubs within the cassette housing. The springs are also connected to the cover with integral living hinges, wherein the hinges provide a certain amount of resiliency for the springs. Ramps are positioned in the cover at spaced distances from the hinge connections with the springs. The ramps are aligned with the hinge connections for underlying portions of the springs and for biasing distal ends of the springs towards engagement with the hubs. Snaps are positioned on the cover between the springs and the ramps or, alternately, are integral with the ramps. The snaps are complementary to portions of the springs for holding the springs on the ramps against the force of the resilient living hinges. The distal end portions of the springs apply spring pressure to the hubs. In one form, the snaps are first and second snaps positioned on opposite sides of the springs for engaging the sides of the springs as they are folded inward within the cover. Alternately, the snaps are blocks aligned with the springs on the cover, and complementary openings in the springs receive and engage the blocks.

In one form, the dust door sides are preformed in angular relation to the top and front of the door.

In another embodiment, the dust door has first and second sides that each have edges hinged to edges of the dust door. The sides incorporate retaining means for connecting the dust door sides to the remainder of the dust door to thereby close the ends of the dust door. Further, the sides of the dust door incorporate a retaining means for attaching and latching the door in the closed position when not in use. These dust door side retaining means are mated with retaining means on the base sides.

In one embodiment, a dust door lock is hinged to a side wall of the base. The lock is foldable downward along the side wall for holding the dust door in closed position.

The rear wall and at least one of the base and side walls incorporate a clasping or engaging means for holding the rear wall upward against the rear edges of the side wall. Further complementary snaps on the cover and at least one of the rear wall or side walls engage to hold the cover downward, with side edges of the cover contacting upper edges of the side walls. The housing in the position with the cover closed is substantially a box having a cover and a base in parallel planes, rear and side walls lying vertically around the edges therebetween, and a living hinged door movably affixed to the front edge of the cover.

A front vertical wall generally extends upward from the base between the forward portions of the first and second side walls. Preferably, an internal forward wall is also positioned somewhat parallel to the front vertical wall and closer to the interior of the molded cassette. The front wall has first and second tape gaps, through which a tape passes out from and into the cassette housing First and second tape guides project forward from the wall, and tape guide pins vertically extend from positions near the tape gaps for angularly redirecting the tape across the tape guide projections. Preferably all of these elements are molded in a single mold to limit the number of parts needed for the cassette.

A preferred cover includes first and second spaced D-shaped openings, across which windows or labels extend to seal to the cover. These windows or labels can consist of paper or paper board, plastic or plastic film, a combination thereof as in a spaghetti box window, or paper/paper board inserted under the plastic film label trap. These may be adhered to the cassette by any suitable means.

The film windows are single sheets bonded to the outside of the cover and sealed along three edges to leave an open edge for the insertion of an identification graphics card.

A preferred housing incorporates cylindrical walls molded within the base spaced around hub openings for receiving and holding hubs for guiding the winding magnetic tape. Tape reeling hubs nest within the hub receiving walls, which extend to the tape gaps for allowing the tape to pass from the reel on the interior of the housing to the exterior of the front wall for reading.

The tape hubs incorporate a means for quickly attaching and holding the end of a magnetic tape leader. The hubs drop into the walled hub receivers to thereby simplify inserting the tape reels in the housing. The hubs can incorporate means for mating with hub lock brakes to effectively lock the hubs into place when the cassette is not in use. The preferred hub is approximately 2.5 inches in diameter and is a one-piece hub design, which is molded by the use of side actions, which form the internal flange and hub outer surfaces. A conventionally sized hub requires the side actions to travel a distance greater than the hub diameter to allow ejection from the mold. This makes a conventional sized hub economically impractical, since it requires a much larger mold and injection molding machine. The 2.5 inch mini-hub reduces the side action travel and allows tighter linear cavity placement, making a one-piece hub viable.

A hub lock brakes the hubs when not in use. The lock is an integrally molded apparatus incorporating two brake release arms which engage the hubs when not in use. A brake release pin separates the arms and allows rotational movement of the hubs.

These and other and further objects and features of the invention are apparent in the disclosure which includes the above and ongoing specification and claims and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an elevational view of the preferred cassette housing with reels and a tape leader.

FIG. 2 is a schematic view of an alternate cassette housing of the present invention showing elements in their molded position.

FIG. 3 is a perspective view of the FIG. 2 embodiment, showing the rear wall folded upward and showing the hub springs folded inward on the cover.

FIG. 4 is a plan view showing the molded position of the housing.

FIG. 5 is an elevation of the molded housing with the rear wall molded or folded upward.

FIG. 6 is a detail showing simplified construction of the living hinges of the cover.

FIG. 7 is a detail of the dust cover of the invention.

FIG. 8 is a detail of an integral dust cover latch.

FIG. 9 is a perspective detail of the one piece molded cassette.

FIG. 10 is an elevational view of one cassette, showing a vertical wall with tape gaps.

FIG. 11 is a detail of the gaps and molded tape guide pins.

FIG. 12 is a detail of an alternative one-piece tape hub with the tape receiving means.

FIG. 13 shows the tape hub receiving slot and hinged tape holding clip.

FIG. 14 shows an alternate view of the tape holding clip and receiving slot combination.

FIG. 15 shows one integrally molded hub spring with integral snap and ramp.

FIG. 16 is a detail of the snap and ramp as shown in FIG. 15.

FIG. 17 is an elevational view of an alternate molded hub spring, snap and ramp.

FIG. 18 is a view of the inward folded hub spring of FIG. 17.

FIG. 19 shows an alternate view of the hub spring snap.

FIG. 20 shows the living hinge of the hub spring.

FIGS. 21 and 22 show a molded hub spring in the originally molded position and folded inward.

FIG. 23 is a sectional detail of the snap/ramp combination shown in FIG. 19.

FIG. 24 shows a detail of a molded hub spring with ramp and alternate snap.

FIG. 25 shows a sectional detail of the FIG. 24 spring folded and snapped.

FIG. 26 shows a top view of one embodiment of the hub lock.

FIG. 27 shows a cutaway detail of a hub lock release post actuating the hub lock release sleeve.

FIG. 28 is a top detail of the hub lock release sleeve.

FIG. 29 is a perspective view of a hub lock similar to one shown in FIG. 26.

FIG. 30 is a detail of the hub lock release sleeve.

FIG. 31 is a plan view of an alternate molded hub lock structure.

FIG. 32 is a front perspective view of an alternate embodiment of the hub lock.

FIG. 33 is a side perspective view of the hub lock shown in FIG. 32.

FIG. 34 is a perspective view of the molded position of the hub lock shown in FIGS. 32 and 33.

FIG. 35 is a top view of the alternate molded position of the hub lock shown in FIG. 34.

FIG. 36 is a top view of the unitized shell or housing with integral mechanics.

FIG. 37 is a perspective side view of the integral guide post with slit metallized guide sleeve, with an alternative snap-on feature.

FIG. 38 is a perspective top view of the guide post in action.

FIG. 39 is an elevated side view of the guide roller and opposite pressure flap in action.

FIG. 40 is an elevated view of the dust door and living hinge incorporating supplemental springs.

FIG. 41 is a side view of the repositioned front wall for the exterior light path.

FIG. 42 shows an alternate composite leaf spring.

FIG. 43 is an elevated side view of a preferred one-piece tape reel, showing a tape clip aperture.

FIG. 44 is an elevated side view of the adherence leadering method of one embodiment of the present invention.

FIG. 45 is an elevated view of a leaf spring incorporating a supplementary support spring.

FIG. 46 is an elevated view of the recessed front wall and corner portion.

FIG. 47 is a cutaway top view of the unitized shell showing detail of the hub lock and hub engagement.

FIG. 48 is an elevated view of one embodiment of the labelled cover.

FIG. 49 is an elevated view of the action of one embodiment of the hub locks.

FIG. 50 is an elevation of a dust door latch.

FIG. 51 is an elevation of an alternative dust door lock using a flexible latch mechanism.

FIGS. 52 and 53 show preferred molds.

FIG. 54 shows a preferred hub.

FIGS. 55 and 56 are top and side views of a preferred brake.

FIG. 57 shows preferred dust door hinges.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring to FIG. 1, a tape cartridge housing is generally indicated by the numeral 1. The housing has a base 3 first and second opposite side walls 5 and 7, a rear wall 9, cover 11, a dust door 13 and hub springs 15 which are all integrally molded. Living hinges 17, 19 and 21 respectively join the base, the rear wall, the cover, and the dust door. Living hinges 21 are formed on extensions 20 along the forward edge of cover 11. When the cover is closed the extensions 20 extend toward the bottom wall 3. Living hinges 23 join the springs to the cover. The base 3 includes an integrally molded front wall 25 which has tape gaps 27 and 29 which are bordered by integrally molded smoothly rounded tape guiding posts 31. The center of the front wall has two integrally molded tape guides 33. Cylindrical female snaps 37 are integrally molded in the base, and complementary male snaps 39 are integrally molded in the cover.

The base incorporates two tape reel-receiving cylindrical walls 40 integrally molded with the base, spaced from hub openings 41 and protruding upwards towards the cover for nesting and holding hubs 42 which hold the tape or leader 45. The walls 40 are intended to surround relatively short lengths of recorded tapes, such as used for advertising. The cassette is supplied closed with a leader that may be cut and spliced or opened ready to drop in a reeled tape before closing. Removable discs 43 allow access to tape clip apertures 49. The tape leader is placed in front of the aperture and the tape clip is forced into the tape clip aperture 49. Hub clips 47 hold the tape in the slots. Flanges 44 on hubs 42 overlie openings 41 and have serrated edges which engage brake teeth.

An axis of rotation or the effective pivot of the living hinges 21 is stepped downward from the cover and is interrupted so that the hinges are not in the tape path.

The cassette further has an alternate drop-in single piece hub lock 51, which is guided by hub lock centering elements 53, as shown in FIG. 2.

As shown in FIGS. 2 and 3, the side walls 5 and 7 have rounded rearward portions 55 with inner edges 57 which engage outer edges 59 of the rear wall. The hub lock centering elements 53 tend to rigidify the rear wall.

The dust door 13 is molded in its downward position, and is joined to the cover by integrally molded living hinge 21. The dust door 13 has a front wall 61 and first and second opposite side walls 63 and 65. Side wall 65 cooperates with an integrally molded dust door latch 67 as will be described in more detail with reference to FIG. 8.

As shown in FIG. 3, the rear wall 9 is folded upward. After dropping the leader-loaded or tape-loaded hubs into the housing, hub springs 15 are folded inwardly and dust door 13 moves upwardly to clear the upper edges of the front wall, as the cover 11 is folded over the base and side walls.

As shown in FIG. 4, the entire housing 1 may be molded with the rear wall 9, cover 11, springs 15 and the top of the dust door 13 in a planar condition. The base 3 has two major openings 69 which act as guides for the reel hubs. A cylindrical upward protrusion 71 is included for insertion of a conventional control. Opening 70 allows the insertion of a conventional brake release pin from the player equipment. Tape gaps 27 and 29 are uniformly formed in the front wall. Tape guiding posts 31 are integrally formed along edges of those openings, and tape directing posts 73 and 75 are formed inside those openings.

A dust door latch, shown in FIG. 8, is integrally formed and connected with a living hinge 68 at the top of side wall 7 in the forward recess 77.

FIG. 5 schematically describes the tape cassette 1 wherein the side portions 5 and 7 and rear wall 9 are vertically molded on the base. The integrally molded front wall 25 is schematically shown. The inner edges 57 of the side wall engage the outer edges 59 of the rear wall. The cover 11 is in the molded position, and the door 13 is connected to the cover via the living hinge schematically shown at 21.

FIG. 6 schematically shows the living hinges 17, 19 and 21 respectively between the base 5, rear wall 9, cover 11, and door 13. As shown in FIG. 1, the cylindrical female snaps on the base and the complementary male snaps 39 on the cover mate and hold the cover fast upon upper edges of the sides of the cassette.

FIG. 7 shows the closed cover 11 upon side 5, with the dust door 13 in the opened position to reveal the front wall 25. The dust door 13 has a living hinge and integrally molded side walls 65, one of which mates with a dust door latch to hold the dust door in the closed position when not in operation. The dust door side wall has an internal ridge or recess 22 for receiving the dust door latch.

FIG. 8 shows the dust door latch 67 integrally molded at the top of recess 77 in the side wall 7 of the cassette. The latch resembles a flap on a living hinge 68 and has protrusions 79 and 81 which engage, respectively, a latch release and the inner edge of the side wall of the dust door. The latch folds downward into the recession. The living hinge provides the required outward urging of the latch to hold the dust door downward. An opposing spring 83 may be added. The latch flap 67 snaps behind an edge 85 in the recess and is pushed outward against the edge by the hinge and opposing spring to force protrusions 79 and 81 toward the plane of the side wall to thereby engage the conventional release and the inner edge of the side wall of the dust door. Insertion of the tape into the player causes a depression of the protrusion 79 and the latch flap within the recess, which causes the disengagement of the protrusion 81 from an opening or inner ridge of the door side, thus allowing the dust door to be raised during operation.

As schematically shown in the details of FIGS. 9-11, the front vertical wall 25 of the cassette incorporates openings 27 and 29, tape guiding posts 31 and integrally molded tape guides 33.

FIG. 12 shows the tape hub for winding the tape within the cassette. The hub has a lower flange 87, an upper disk or flange 43 and a winding drum 89 positioned therebetween. The winding drum incorporates a tape clip aperture 49 for receiving a tape. Clip 47 is complementary to the slot for holding the tape on the drum. The clip 47 may be hinged to the drum by living hinge 91, as shown in FIGS. 12 and 13. To load tapes into the cassette, the user places the leader in front of the tape clip aperture 49, swings up the clip, and pushes the clip and leader into slot 49. The tape end is inserted into the opening, and the clip is pushed upward into a closed position, wherein the edges 93 of the clip engage the sides 94 of the slot. Alternately, as shown in FIGS. 1 and 14, the upper disk or flange 43 of the hub is removable to expose a slidable clip 47 which slides out of the slot 49 normally obstructed by the removable disk 43. The edges 47 slide into grooves 97 in the slot 49 to engage the clip with the hub. The leader o tape 45 is placed between the clip and the hub and is thus, held for winding upon the drum.

Four fingers are formed by telescoping shut offs in the mold, which come up through the openings in bottom flange 44.

As shown in FIGS. 15-25, the leaf springs 15 are integrally molded with the cover 11 and are attached via living hinges 23. In the FIG. 1 embodiment, the hinges are molded so as to protrude inwardly and upwardly from the curved portion of a D-shaped cavity 99 in the cover of the cassette. Covering the cavity on the side opposite the hinged spring is a clear envelope for labels, which may be bonded to the cover, or a plastic see through window for viewing the tape. In the FIGS. 15-25 embodiments, the springs are molded so as to extend outwardly from the edge 12 of the cover, with the hinge 23 on the edge. To activate the springs, the springs are folded inwardly about the hinges toward the inner portion of the cover, with the hinge providing an opposing force to that action. A ramp, a snap, a spring engaging ramp, or snap 101, or both hold the compressed spring. A ramp 103 provides a fulcrum adjacent the engagement but more distal from the hinge than the engagement.

The engagement 101 may take a variety of forms. In one embodiment, a wedge shaped protrusion 105 on the spring fits into a complementary slot 107 cut into the ramp, as shown in FIGS. 15 and 16. FIGS. 17 and 18 show an embodiment where the engaging means consist of a pair of hook-like clasps 109 protruding from the cover and engaging the sides of the leaf spring, while using the ramp 103 as a fulcrum for the spring. FIGS. 17 and 18 show the molded spring and the spring and action respectively.

FIG. 19 discloses an alternate leaf spring 15 incorporating a protruding ramp snap 111 molded onto the leaf spring, which fits into recess 112 in the cover 11 and snaps therein. However, the mating of the ramp snap and recess is such that the former protrudes somewhat and acts as a ramp while still holding the leaf spring in a cantilever position upon the cover.

FIG. 20 shows a preferred living hinge 23 as disclosed between the leaf spring 15 and the cover 11. FIGS. 21 and 22 show the action of the molded leaf spring 15 as bending at the living hinge 23 in a cantilevered manner towards the inside of the cover 11 to thereby provide a hub spring at the distal end 16.

FIGS. 23, 24 and 25 show one preferred embodiment of the leaf spring. Plural cylindrical protrusions 113 molded upon the leaf spring snap into complementary snap members 114 molded into the cover between the hinge 23 and the ramp 103. FIGS. 23 and 25 show cutaway versions of the molded and active positions of that embodiment.

The video cassette incorporates a hub lock or brake mechanism for preventing the rotation of the hubs during non use. Several embodiments of the present invention's hub lock are described in FIGS. 26-35. The constructions include an embodiment integrally molded with the cassette or, alternatively, an embodiment which can be separately molded and subsequently dropped into the cassette. One embodiment of the present hub lock 51 is shown in FIG. 26. The hub lock is situated within the housing whereby two hub locking arms 115 engage the serrated or toothed edges of the hub flanges when in the relaxed position, as shown in FIG. 4. The brake 51 incorporates a brake release sleeve 117, which is halved and connected to two respective brake levers 119, which are subsequently connected to hub release arms 121, which oppositely extend from the respective levers. A fulcrum 123 is positioned substantially mid-way through the levers and is connected therebetween so as to provide a pivoting means between the halves of the brake release sleeve and the respective arms through each lever. Further, each lever incorporates a pivot sleeve 125 for allowing the levers to pivot when a force is applied to either the brake release sleeve or one of the hub release arms. The pivot sleeves rest upon pivot pins 127 which are molded into the base of the housing. A resilient spring 129 is positioned between the two levers closer to the arms than the fulcrum, so as to exert an outward force on the adjacent length of the lever, thereby causing the opposite ends of the lever to come together and substantially close the two halves of the brake release sleeve. In this position, the hub catch portion of the arms engage the hubs.

However, as shown in FIG. 27, when the cassette is in a player, a brake release pin enters the base of the cassette through the brake release orifice 73, as shown in FIG. 4. The brake release pin 133 pushes apart the two halves of the sleeve and thereby causes an outward force upon the adjacent portions of the lever. The resultant opposite force is an inward movement of the opposite ends of the levers proximal the arms and the subsequent inward movement of the arms. That causes the disengagement of the hub latches 131 from the hub flanges.

Alternately, hub lock 117, as shown in FIGS. 32-35, incorporates a brake support 135, a brake shelf 137, and a brake axle 139. Two brake levers 119 connected to the brake shelf and abut two respective brake arms 121. In that embodiment of the hub lock mechanism, a brake support 135 holds the hub lock between the hubs. The resting position results in the engagement of the brake arms 121 with the respective hub flanges. In that position, the brake shelf 137 lies over the hub release orifice. When the cassette is inserted into a machine, a hub release pin forces the bottom of the shelf in an upward movement and in a rotation about the brake axle 139 at the opposite end of the shelf. Attached adjacently thereto on each side of the brake shelf are the brake levers 1-9 which protrude substantially perpendicularly from the shelf. Abutting these levers are drive plates 141 connected to the brake arms. The rotation of the brake shelf causes a similar rotation of the brake levers, which subsequently actuates identical inward movements of the drive plates, pulling the brake arms inward. The inward movement of the drive plates causes the rotation of the brake arms due to the sliding connection therebetween. The brake arms swing inward towards the shelf and hub engaging edges 143 disengage the hub flanges.

The upward force of the release pin upon the brake shelf is opposed by living hinges 145 between the brake arm 121 and the brake support 135. The normal position of the brake arms is substantially planar to the brake support. The positioning of the perpendicularly connected drive brakes within the edges of the brake levers results in downward pressure upon the brake shelf.

FIGS. 34 and 35 show the hub brake as molded, before the drive plates 141 are placed within the brake levers 119. The living hinge 145 between the brake arm 121 and the brake support 135 is in the closed position.

While two preferred embodiments of the brake have been described, any braking mechanism could be substituted without taking away from the overall invention of the one piece integrally molded recyclable cassette.

The embodiments for the window openings in the cover range from small to large. However, the preferred embodiment includes a real leaf spring or hub spring internal to the opening. The window can be opaque with no visibility, or clear with a see-through label, see-through plastic film label trap, or see-through spaghetti box window in paper/paper board label. An alternate cover attachment is a label which attaches to the cover for tape identification. The label can be of paper or paper board, plastic or plastic film, a combination thereof (a la spaghetti box window), or paper/paper board inserted under plastic film label trap. The label can be adhered to the cover by snaps, pressure-sensitive over-label, direct thermal welds, or molded-in insert card.

Other features include an integrally molded pressure flap 150 as shown in FIGS. 36 and 39, which controls tension on the tape at the front of the apparatus. A penetrating shut off comes through the opening and forms the bottom of the pressure flap. The pressure flap works in conjunction with a guide pin or pin and roller. The pin may be a rolling element. Debris embeds in plastic, scratching tape. Both pins can be integrally molded with the apparatus to provide their function. The guide post can be made of one piece with the integrally molded plastic cassette. Component guide rollers may be made of metal guide pins or plastic pins over which other rollers can slide. These guide pins or posts substantially control the flow of the tape from the interior to the exterior, and vice versa, and are thereby fitted to the proximal width of the tape to substantially control any wavering or lateral movement caused in the process of running the tape. This can be accomplished by including upper and lower flanges which nearly abut the edges of the tape. FIGS. 37, 38 and 39 substantially show the pressure flap and flanged tape guide in action. FIG. 37 shows guide pins comprised of an integral guide pin 152, incorporating a molded support rib 154 and lower flange 156. A guide pin sleeve 158 slides over the integral guide pin and snaps into place with snaps 159, which engage surface 155. The guide post sleeve has an upper flange 160 and can be constructed of plastic with an optional stainless steel metallized surface. The preferred construction is a polished plastic pin with an optional stainless steel metallized surface. A cylindrical polish in the particular location in the mold replaces the standard draw polish. FIG. 38 shows the integral guide post and sleeve in place with a tape constrained by the upper and lower flanges. FIG. 39 shows a guide pin/pressure flap construction, wherein an integral guide pin 162 incorporates a guide roller 164, which abuts the tape. Opposite the guide roller lies the pressure flap 50, previously shown in FIG. 36.

FIG. 36 is a top view of the integrally molded tape cassette showing the unitized shell or housing 1, having a cover 11, base 3 and dust door 13. The entire assembly folds up to enclose removable tape hubs. In the embodiment as shown in FIG. 36, the hub or wheel lock 51 is of a one-piece construction that is integrally molded with the base of the cassette. The separate elements (i.e. base, rear wall, cover and dust door) are all attached, incorporating living hinges. In one embodiment, the vitality of these hinges can be assisted by incorporating snap-in wires or springs, which are easily removable and can be recyclable.

FIG. 4 shows the living hinged dust door 13 with living hinge 21. In this embodiment, a spring slot 167 can hold either of two springs 168 and 170 to assist the living hinge to give the dust door the force to close when out of a video player.

FIG. 41 is an alternate configuration for the front wall of the low cost video cassette, wherein the front wall 25 is repositioned rearwardly to allow an external light source path 172 for detecting the clear leader of the video cassette tape.

FIG. 42 shows a composite tape hub spring 174, which is constructed with reinforcement wires 176 and plastic 178. It may be constructed in injection molding or wire plastic extruding processes. The wire and plastic extrusion process is continuous, wherein the composite extrusion is cut to length, stamped and formed to provide the structure as shown in FIG. 42. The extruded spring has two opposite arms 180 and 182, which extend from a base portion 179. The base portion has plural holes 183, which mate with protrusions 184 on the cover of the video cassette, as shown in FIG. 36. Thus, the base portion locks into place on the cover, wherein the arms extend outwardly and downward from the cover towards the center portions of the hubs.

FIG. 36 further shows rings 186 around the hub holes or openings 41 for allowing thinning of the wall in the base without loss of hub reference height. This restricts the movement of the hub within the cassette and lessens damage that additional hub movement can cause to the tape on the hub.

Another option is provided for the hub mechanism, wherein the hub is made of one piece, such as shown in FIG. 43, and the attachment of the tape leader is a simple process. The one-piece hub can provide clip-less leadering, such as shown in FIG. 44, wherein the leader welds or adheres to itself or to the hub. Further, a vacuum port or slit can be provided in the hub for self-threading of the leader before welding/adhering of the leader to the hub. These methods are options to the clip functions previously described.

FIGS. 43 shows an alternate hub for clip leadering. FIG. 43 shows the hub 42 incorporating a tape clip aperture 184 for fixing the leader. FIG. 44 shows an alternate hub 42, wherein a tape or leader 45 winds around the hub and adheres to the hub or to itself at the 360. interval 185 through a conventional adhesive or adhesive reactive to an adhering element 186 which can apply heat, voltage, light or other reactive means.

Regular leader tape is wrapped and welded to itself or to the hub. Leader tape is coated with thermal adhesive softening at about 300°-350° F. The tape leader is run across the surface, and the surface of the hub and the leader are heated to the softening point of the adhesive.

While supplementary springs can be utilized in the hinge of the living hinge door, it is also feasible for supplementary springs or supports to be utilized in other elements of the unitized shell video cassette.

FIG. 45 shows an alternate leaf spring 188, which incorporates clamping means 189 and holding means 190 for engaging and holding a supplementary rod functioning as a spring 191, which assists the integrally molded leaf spring in its action against the hub at its distal end 192.

FIG. 46 schematically shows an embodiment of the unitized shell.

FIG. 47 is a cutaway view of the unitized shell or housing with the tape hubs 42 in place. The cutaway figure shows the engagement of the hub lock 51, having hub release arms 121 which engage gear-like indentations 188 on the reel.

FIG. 48 shows a side elevational view of an embodiment of the unitized shell which incorporates a means for providing a window 190 on the cover of the unitized shell. The window is provided by an indentation or label trap 192 for receiving a paper/paper board card. The indentation 192 has four edge slots 193 for engaging the corners of the card and holding it therein. Further, a clear or semi-clear film 196 covers the label trap and adheres or snaps to the cover along ledge portions 197 around the trap or indentation 192.

In one embodiment, a clear, semi-clear or printed film is adhered to the top surface. An embodiment may weld or adhere a label trap to the top, leaving one or two edges open to slip a card under the trap.

FIG. 49 shows the preferred unitary hub lock 51, previously shown in FIGS. 26-31. As shown in the present figure, the hub lock is engaging the hub at hub release arms 121. However, the engagement of the tape in the tape recorder causes a brake release pin incorporated in the video cassette recorder to be forced upwardly into the pivot sleeve 125 to thereby cause the action as shown by the series of blackened arrows. In other words, the halves of the brake sleeve are forced apart, which thereby causes the inward movement of the brake release arms and the subsequent release of the brake from the hubs.

Surface 51 in the area of tip 121 and the bottom surface of 121 are formed by penetrating shut offs. The split hub lock is designed so that each hub lock can operate independently. Independent action is important to ensure locking during shipment.

FIGS. 50 and 51 show opposite elevated side views of two alternate methods of forming the dust door latch 167 from that as shown in FIG. 8. The figures show the latch in the molded and ready positions respectively.

FIGS. 52 and 53 show preferred molds 180 with side actions 182 for forming a hub 184.

FIG. 54 shows a preferred hub 184.

FIGS. 55 and 56 ar top and side views of a preferred brake 186 showing pivots 188, release pin receiver 190, and engaging teeth 192.

FIG. 56 shows the hole 194 in base 3 through which the brake is formed.

FIG. 57 shows preferred dust door hinges 21.

The preferred material for the shell and dust door is polypropylene. High density polyethylene is suitable. Impact styrene may be used. The polypropylene homopolymer gives the best living hinge life, and the co-polymer gives better impact resistance. Polypropylene tailored by blending the homopolymer and co-polymer to achieve the best combination of hinge life is preferred. Polypropylene is also the least expensive polymer by virtue of its low cost and low specific gravity.

High density polyethylene is also a potential material. It has less of a hinge life but could be adequate. High density polyethylene has good cold temperature impact strength. The polymer is more expensive than polypropylene, although recycled high density polyethylene is in wide abundance and is inexpensive. Recycled high density polyethylene and recycled polypropylene may give good cost/performance value.

Polystyrene, particularly modified polymers, could be used, but hinge life would be limited.

While the invention has been described with reference to specific embodiments, modifications and variations may be constructed without departing from the scope of the invention, which is defined in the following claims. 

We claim:
 1. A unitary video tape cassette housing, comprising a base, a rear wall connected to the base, first and second opposite side walls connected to the base and a cover integrally hinged to the rear wall by a cover hinge, side edges of the rear wall in contact with rear edges of the side walls, connectors holding side edges of the cover in contact with upper edges of the side walls and further comprising spaced downward extensions along side edges of the cover, the extensions extending downward toward the base, dust door living hinges integrally formed on forward edges of the downward extensions, and a dust door integrally molded on the dust door living hinges for hinging the dust door on the downward extensions of the cover for permitting movement of the dust door between a raised position and a lowered position covering a front of the cassette housing, the dust door living hinges being spaced to allow passage of the tape between the living hinges and to allow tape reels to be partially positioned between the dust door living hinges.
 2. The apparatus of claim 1, wherein the dust door hinge comprises a living hinge integrally formed between the dust door and the cover.
 3. The apparatus of claim 1, wherein the cover hinge comprises a living hinge integrally formed between an upper edge of the rear wall and a rear edge of the cover.
 4. The apparatus of claim 1, further comprising a living hinge integrally formed between a rear edge of the base and a bottom edge of the rear wall.
 5. The apparatus of claim 1, further comprising integrally formed first and second leaf springs hinged at first and second side edges of the cover for resting atop hubs within the cassette housing.
 6. The apparatus of claim 5, wherein the springs are hinged to the cover with integral living spring hinges.
 7. The apparatus of claim 1, further comprising an integrally molded dust door lock hinged to an upper edge of one of the side walls by an integrally formed living hinge and foldable downward towards the base along and on an outer side of the side wall for engaging the dust door and holding the dust door in closed position.
 8. The apparatus of claim 1, further comprising complementary connectors on the rear wall and at least one of the base and side walls for holding the rear wall upward with side edges engaging rear edges of the side walls and second complementary snaps on the cover and at least one of base, the rear wall and side walls for holding the cover downward with side edges of the cover contacting upper edges of the side walls.
 9. The apparatus of claim 1, further comprising a front front wall generally extending between forward portions of the first and second side walls and having first and second tape gaps in the front wall for passing tape out from and into the cassette housing.
 10. The apparatus of claim 9, further comprising first and second tape guides projected forward from the wall and tape guide pins vertically extending from positions near forward edges of the base for angularly redirecting the tape.
 11. The apparatus of claim 9, wherein the guides and pins are integrally molded within a single mold.
 12. The apparatus of claim 1, further comprising first and second spaced openings in the cover, with film windows extending over the openings and sealed to the cover around at least portions of the openings.
 13. The apparatus of claim 12, wherein the film is sealed around the openings and along one edge between the openings, and wherein an open unsealed edge of the film is located in a central portion of one elongated edge of the cover for forming a pocket with the film window between the openings for inserting an identification graphics card in the pocket.
 14. The apparatus of claim 1, further comprising a window having a single sheet bonded to an outside of the cover and sealed along two o three edges thereof, leaving an open edge for insertion of an identification label selected from the group consisting of: a graphics card; a snap-in graphics card and an adhered graphics card.
 15. The apparatus of claim 1, further comprising cylindrical walls molded with the base for receiving and holding hubs for winding magnetic tape.
 16. The apparatus of claim 15, wherein the hubs nest within the cylindrical walls.
 17. The apparatus of claim 16, further comprising the tape hubs having toothed flanges positioned on the base and a one piece drop in brake for detachably holding the toothed flanges in locked condition.
 18. The apparatus of claim 15, further comprising a front wall molded adjacent the cylindrical walls and spaced away from front edges of the base and cover, and tape guides connected to the base portions cantilevered beyond of the front wall.
 19. The apparatus of claim 1, further comprising a window having a single sheet bonded to an outside of the cover and sealed along two or three edges thereof, leaving an open edge for insertion of an identification card, wherein the window is a spaghetti box type window.
 20. A unitary video tape cassette housing, comprising a base, a rear wall connected to the base, first and second opposite side walls connected to the base and a cover integrally hinged to the rear wall by a cover hinge, a dust door pivoted on a front of the housing, side edges of the rear wall in contact with rear edges of the side walls, connectors holding side edges of the cover in contact with upper edges of the side walls and integrally formed dust door hinge for hinging the dust door on the cover for permitting movement of the dust door between a raised position and a lowered position covering a front of the cassette housing, integrally formed first and second leaf springs hinged at first and second side edges of the cover for resting atop hubs within the cassette housing, wherein the springs are hinged to the cover with integral living hinges, and integrally formed ramps positioned in the cover spaced from the hinges with the springs and aligned therewith for overlying portions of the springs and biasing distal ends of the springs toward engagement with the hubs.
 21. The apparatus of claim 20, further comprising snaps positioned on the cover between the springs hinges and the ramps for securing ends of the springs remote from the hubs to the cover.
 22. The apparatus of claim 21, wherein the snaps comprise first and second snaps on opposite sides of the springs for engaging sides of the springs as they are folded inward within the cover.
 23. The apparatus of claim 21, wherein the snaps comprise blocks aligned wtih the springs and complementary openings in the springs for receiving and engaging the blocks.
 24. A unitary video cassette case having a molded base, comprising a bottom wall, first and second opposite side walls and a front wall integrally formed together and having tape-passing gaps in the front wall, a first living hinge along a rearward edge of the bottom wall, a rear wall joined to the first living hinge, a second living hinge along a remote edge of the rear wall, a top wall having a rear edge joined to the second living hinge, the top wall having first and second spaced side edge portions for overlying the side walls and having a front edge, further comprising downward extensions along side edges of the top wall extending downward toward the bottom wall, dust door living hinges integrally formed on forward edges of the downward extensions, and a dust door integrally molded on the dust door living hinges for folding upward and downward on the dust door living hinges, the dust door living hinges being interrupted to allow passage of the tape between the dust door living hinges and to allow tape reel into position between the dust door living hinges, and connectors connected to the top wall and to at least one of the bottom wall, the first and second side walls and the front wall for holding the case assembled wtih the top wall overlying the front and side walls and the dust door having a portion extended in front of the front wall.
 25. The apparatus of claim 24, further comprising first and second cylindrical tape guiding walls extending upward from the bottom wall around first and second hub receiving openings in the bottom wall and further comprising rounded posts formed in the front wall adjacent tape passing slots leading to the cylindrical walls for guiding tape in and out of the cylindrical walls.
 26. The apparatus of claim 25, wherein the posts have connection means at the upper ends interfitting with complementary connection means positioned on a lower side of the top wall for holding the top wall assembled on the posts.
 27. The apparatus of claim 25, further comprising an integrally formed brake mounted between the cylindrical walls and having first and second brake levers and first and second brake teeth extending from remote portions of brake levers through openings in the cylindrical walls for engaging and braking tape reels having toothed flanges on a base of each tape hub installed within the cylindrical walls.
 28. The apparatus of claim 25, further comprising a portion of the bottom wall extending from an outward side of the front wall and tape guides extending upward from the bottom wall toward the dust door, the tape guides having vertical wall portions and molded posts, the molded posts being mounted near the rounded posts on the front wall for redirecting the tape passing through the slotted openings in the front wall around the tape guide posts and along a front edge of the shelf portions and the vertical tape guides.
 29. The apparatus of claim 25, further comprising first and second tape reels fitted within the tape guiding walls.
 30. The apparatus of claim 24, further comprising reel engaging springs integrally formed with the top wall and extending downward and inward into contact with tops of tape winding reel hubs positioned on the bottom wall in communication with reel openings in the bottom wall.
 31. The apparatus of claim 24, further comprising a dust door lock integrally formed on a living hinge at the top of one side wall for outwardly urging against an inner surface of the dust door.
 32. The apparatus of claim 24, further comprising a hub reel brake release opening in the bottom wall and hub reel brake guides integrally formed on the bottom wall near the brake release opening and an integrally formed hub reel brake having a release pin receiver, guide legs positioned against the brake guides, brake legs extending outward from the guide levers and brake teeth projecting from remote ends of the brake levers for engaging a tape reel and a spring connected between the guide legs.
 33. The apparatus of claim 24, further comprising a brake actuating opening in the bottom wall, reel brake holders positioned on the bottom wall near the brake release opening and an integrally formed reel brake having a release contacting shelf overlying the release opening, a horizontal axle connected to the shelf for contacting the brake holder, vertical brake release plates connected to the release contacting shelf for moving in an arc about the axle as the release shelf is raised around the axle, a brake beam holder connected to the shelf near the axle by a fourth living hinge, brake beams connected to the holder by fifth and sixth living hinges for moving in generally horizontal arcs, brake teeth connected to the brake beams for engaging the tape winding reels.
 34. A unitary video cassette case having a molded base, comprising a bottom wall, first and second opposite side walls and a front wall integrally formed together and having tape-passing gaps in the front wall, a first living hinge along a rearward edge of the bottom wall, a rear wall joined to the first living hinge, a second living hinge along a remote edge of the rear wall, a top wall having a rear edge joined to the second living hinge, the top wall having first and second spaced side edge portions for overlying the side walls and having a front edge, a third living hinge connected to the front edge of the top wall, a dust door having a rear edge connected to the third living hinge and connectors connected to the top wall and to at least one of the bottom wall, the first and second side walls and the front wall for holding the case assembled wtih the top wall overlying the front and side walls and the dust cover having a portion extended in front of the front wall, and a hub spring connector having complementary portions connected to a lower surface of the top wall and to an upper surface of the spring for holding the spring on the top wall.
 35. A unitary plastic video tape cassette shell comprising an integrally formed bottom wall connected to first and second side walls, a rear wall, a front wall and a top wall, with window openings in the top wall, and with reel leaf springs formed with the top wall and extending into the openings, further comprising downward extensions along side edges of the top wall extending downward toward the bottom wall, dust door living hinges integrally formed on forward edges of the downward extensions, and a dust door integrally molded on the dust door living hinges for folding upward and downward on the dust door living hinges, the dust door living hinges being interrupted to allow passage of the tape between the dust door living hinges and to allow tape reel into position between the dust door living hinges, wherein the shell is constructed entirely of a plastic material selected from the group of plastic materials consisting of: polypropylene; high density polyethylene; and recycled polypropylene and high density polyethylene.
 36. The shell of claim 35, further comprising a film adhered to the top wall and covering the openings.
 37. The shell of claim 36, wherein the film is a label.
 38. The shell of claim 36, wherein the film forms a label trap between the openings.
 39. The shell of claim 36, further comprising a paper board label connected to the film.
 40. The shell of claim 36, further comprising receivers in the shell, and wherein the film comprises an insert card held in the receivers.
 41. The shell of claim 35, further comprising integrally formed extensions extending toward the top wall from the bottom wall for entrapping a tape within the shell.
 42. The shell of claim 35, further comprising inward extensions on the top wall extending toward the bottom wall for supporting tape guide posts between the top and bottom walls.
 43. The apparatus of claim 35, wherein the front wall is displaced inward from a front edge of the bottom wall toward the rear wall for providing an uninterrupted external light source path.
 44. The shell of claim 35, further comprising metal hinge reinforcements within the living hinges connected to the dust door for increasing spring force of the living hinges.
 45. The shell of claim 38, further comprising plastic springs connected to the top wall and to the dust door for supplementing spring force of the dust door connected living hinges.
 46. The shell of claim 45, further comprising hubs positioned in the shell between the top wall and bottom wall, the hubs having one-piece construction formed in side action dies which form the internal flanges and hub outer diameter surfaces.
 47. The shell of claim 46, further comprising a leader attached to the hub by bonding.
 48. The shell of claim 46, further comprising an integrally formed reel lock mounted in the shell between the top wall and the bottom wall, the integrally formed reel lock having first and second longitudinally extending legs and first and first and second pivots respectively connected medially to the longitudinally extending legs, reel engaging teeth extending outward from first ends of the legs for engaging a reel having teeth along an outer periphery of a flange of the reel and complementary pin receiving brake releasers mounted on second ends of the legs for moving the second ends outward and thereby moving the legs about the pivots and moving the first ends of the legs inward for releasing the locks.
 49. The shell of claim 35, further comprising a dust door connected to the shell near the front wall thereof for selectively covering and uncovering a tape, and to the door latch connected to one side wall of the shell adjacent the dust door, the door latch comprising a living hinge connected to an upper portion of the side wall and a flap extending downward along a forward portion of the side wall beneath the dust door, and complementary engagement means on the flap and dust door for holding the flap and dust door engaged until the flap is pushed inward for disengagement of the dust door
 50. The shell of claim 35, further comprising an integral pin formed on and extending from the bottom wall toward the bottom wall, and a guide post on the pin.
 51. The shell of claim 50, wherein the guide post is integrally formed.
 52. The shell of claim 50, wherein the guide posts are formed by metallization deposition on the pins.
 53. The shell of claim 35, further comprising tape guiding openings in the front wall and a pressure flap integrally formed with the shell and extending toward one of the tape guiding openings for pressing a tape against the one of the openings.
 54. The shell of claim 35, constructed of polypropylene material.
 55. The shell of claim 35, constructed of a polypropylene material selected from the group of polypropylene materials consisting of a polypropylene homopolymer, a polypropylene co-polymer, a blend of polypropylene homopolymer and a polypropylene co-polymer; and a blend of polypropylene homopolymer and polypropylene co-polymers.
 56. The shell of claim 35, further comprising an integral pin extending from the bottom wall toward the top wall, and a guide post pin. 